Transcript
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 1/24
ii
DESIGN AND DEVELOPMENT OF 1-SEATED URBAN CAR CHASSIS USING
ALUMINIUM
FAZLIANA BINTI FAUZUN
Report submitted in partial fulfillment of the requirements
for the award of the degree of
Bachelor of Mechanical Engineering
Faculty of Mechanical Engineering
UNIVERSITI MALAYSIA PAHANG
DECEMBER 2010
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 2/24
iv
STUDENT’S DECLARATION
I hereby declare that the work in this project is my own except for quotations and
summaries which have been duly acknowledged. The project has not been accepted for
any degree and is not concurrently submitted for award of other degree.
Name: FAZLIANA BINTI FAUZUN
ID Number: MA 07063
Date: 6 DECEMBER 2010
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 3/24
vi
ACKNOWLEDGEMENTS
First and foremost, I am grateful and would like to express my sincere gratitude
to my supervisor Dr. Sugeng Ariyono for his invaluable guidance, germinal ideas,continuous encouragement and constant support in making this research possible. He
has always impressed me with his outstanding professional conduct, his strong
conviction for science, and his belief that a Degree program is only a start of life-long
learning experiences. I am appreciating his consistent support from the first day I
applied to graduate program until this moment. I am very grateful for his progressive
vision about my training and his tolerance of my mistakes.
Sincerely, I also would like to express very special thanks to the all members of
the staff of Mechanical Engineering Department, who helped me in many ways
including the preparation of this study. I would like to thank the authority of University
Malaysia Pahang (UMP) for providing us with good environment and facilities tocomplete this study. Many special thanks go to members of research group for their
excellent co-operation, inspirations and supports during this study.
Finally, I acknowledge my sincere indebtedness and gratitude to my parents for
their love, understanding and sacrifice throughout my life. An honourable mention goes
to my love and my friends for their supports on me in completing this study. I cannot
find the appropriate words that could properly describe my appreciation for their
devotion, support and faith in my ability to attain my goals. I would like to acknowledge
their comments and suggestions, which was crucial for the successful completion of this
study.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 4/24
vii
ABSTRACT
This thesis deals with the design and development of the 1-seated urban car chassis
using aluminium. The objective of this thesis is to develop the general procedures of analyzing the existing design of Shell Eco-marathon car chassis and designing a new
chassis with several enhancements using aluminium as material. The thesis describes
finite element analysis techniques to predict the displacement magnitude and identify
the worst stress locates in the structures. Stainless steel AISI type 304 and aluminium
alloy T6 6063 were studied in this thesis which commonly used for a chassis structure
in industry. The structural of three-dimensional solid modeling of the chassis was
developed using Solidworks software. The strategy of validation of finite element model
was developed. The finite element analysis was then performed using ALGOR Fempro.
Both chassis structure was analyzed using the static stress with linear material models
approaches. Finally, the displacement magnitude of the structure and worst stress are
obtained. From the results, it is observed that the displacement magnitude of newchassis is decreasing about 40% compared to the existing design. The existing design
which used the stainless steel as material selection also is found to have higher worst
stress compared with the aluminium chassis. Besides, comparing both designs founds
the overall chassis weight of aluminium chassis is reduced about 30%. The obtained
results indicate that using aluminium gives the chassis structure higher stiffness and
light in weight. It also found that the rectangular tubes aluminium gives stiffer structure
compared to aluminium pipes. The results conclude that using aluminium with larger
cross sectional tubes area gives higher stiffness chassis structure. Therefore, using
rectangular tubes aluminium promising higher stiffness structure and weight saving.
The durability assessment results are significant to improve the chassis design at the
developing stage. The results can also significantly reduce the cost and time in
fabricating the chassis during the events, and improve reliability and user confidence.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 5/24
viii
ABSTRAK
Tesis ini membincangkan tentang reka bentuk dan pembangunan casis kereta bandar
satu tempat duduk dari bahan aluminium. Objektif tesis ini adalah untuk membangunkan prosedur umum dalam menganalisis reka bentuk casis kereta Shell Eco-
marathon yang sedia ada dan mereka bentuk satu reka bentuk casis yang baharu dengan
beberapa tambahan dengan menggunakan bahan aluminium. Tesis ini juga menjelaskan
teknik analisis elemen terhad untuk meramalkan perubahan magnitud dan mengenal
pasti kedudukan tekanan terburuk dalam struktur. Besi tahan karat AISI 304 dan aloy
aluminium T6 6063 dikaji dalam tesis ini yang kebiasaannya digunakan untuk struktur
casis dalam industri. Penstrukturan model padu tiga dimensi casis telah dibangunkan
menggunakan perisian Solidworks. Strategi juga mengenal pasti model elemen terhad
telah dibangunkan. Analisis elemen terhad pula telah dilakukan menggunakan ALGOR
Fempro. Kedua-dua struktur casis telah dianalisis menggunakan tekanan statik dengan
pendekatan model material mendatar. Akhirnya, perubahan magnitud struktur dantekanan terburuk diperolehi. Dari keputusan yang diperoleh, perubahan magnitud casis
yang baharu diperhatikan mengalami perubahan lebih kecil berbanding reka bentuk
yang sedia ada. Reka bentuk sedia ada yang menggunakan besi tahan karat sebagai
bahan pilihan telah didapati mempunyai tekanan terburuk yang lebih tinggi berbanding
casis aluminium. Selain itu juga, dengan membandingkan kedua-dua reka bentuk
mendapati bahawa berat casis keseluruhan bagi aluminium casis telah dikurangkan.
Keputusan yang diperoleh menunjukkan bahawa menggunakan aluminium memberikan
struktur casis kepegunan yang lebih tinggi dan ringan. Keputusan ini juga mendapati
bahawa tiub aluminium sesegi empat sama menghasilkan lebih kepegunan berbanding
dengan paip aluminium. Keputusan merangkumkan bahawa menggunakan aluminium
dengan luas keratan rentas yang lebih besar menghasilkan struktur casis yang lebih
pegun. Oleh yang demikian, menggunakan tiub aluminium sesegi empat sama
menjanjikan struktur yang tinggi kepegunan dan ringan. Keputusan penilaian ketahanan
adalah penting dalam mempertingkatkan reka bentuk casis pada fasa pembangunan.
Hasil keputusan juga dengan nyata sekali mengurangkan kos dan masa membina casis
semasa hari acara dan meningkatkan kepercayaan pengguna.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 6/24
ix
TABLE OF CONTENTS
Page
SUPERVISOR’ DECLARATION iii
STUDENT’S DECLARATION iv
DEDICATION v
ACKNWOLEDGEMENTS vi
ABSTRACT vii
ABSTRAK viii
TABLE OF CONTENTS ix
LIST OF TABLES xii
LIST OF FIGURES xiii
LIST OF SYMBOLS xv
LIST OF ABBREVIATIONS xvi
CHAPTER 1 INTRODUCTION
1.1 Project Background 1
1.2 Problem Statement 4
1.3 Objectives of the Project 5
1.4 Project Scope 5
1.5 Project Methodology 5
1.6 Structure of the thesis 8
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 10
2.2 Introduction of Shell Eco-marathon Asia 2010 11
2.3 Type of Chassis of an Urban Car and Current Design 12
2.4 Advantages and Disadvantages of Using aluminium for a
Chassis
2.4.1 Advantages 15
2.4.2 Disadvantages 17
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 7/24
x
2.5 Summary 18
CHAPTER 3 ANALYSIS OF EXISTING DESIGN AND
PROPOSED A NEW CONCEPT OF THE CHASSIS
OF AN URBAN CAR
3.1 Introduction 19
3.2 Parameter selection 20
3.3 Existing design of Shell Eco-marathon Asia 2010 21
3.3.1 Finite Element Analysis (FEA) using Algor 23
3.3.2 Discussion 29
3.4 Properties of Aluminium based on experiment 30
3.5 Summary of the chapter 3 34
CHAPTER 4 DETAIL DESIGN OF PROPOSED SELECTED
DESIGN
4.1 Introduction 35
4.2 Analysis of the new design 36
4.2.1 Design sketching 36
4.2.2 Finite Element Analysis (FEA) using Algor 37
4.2.3 Analysis Comparison Result 41
4.3 Analysis of the materials 42
4.3.1 Comparison of Finite Element Analysis between
aluminium pipes and aluminium rectangular tubes
42
4.4 Discussion 46
CHAPTER 5 CONCLUSSION AND RECOMMENDATIONS
5.1 Conclusions 49
5.2 Recommendations 50
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 8/24
xi
REFERENCES 52
APPENDICES 54
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 9/24
xii
LIST OF TABLES
Table No. Title Page
1.1 The mechanical properties of aluminium 3
3.1 List of parameter involved 20
3.2 The properties of Stainless steel AISI 304 pipes 23
3.3 The analyses result of existing chassis of Shell Eco-marathon 24
3.4 The mechanical properties of AISI Type 304 29
3.5 Typical chemical composition for aluminium alloy 6063 32
3.6 Typical mechanical properties for aluminium alloy 6063 32
3.7 Typical physical properties for aluminium alloy 6063 33
3.8 The fabrication of aluminium alloy 6063 33
4.1 The comparison result between the existing design and the
new design
41
4.2 The result data of the force applied on the roll bar 43
4.3 The result data of the force applied on the driver’s position and
engine compartment.
44
4.4 The result data of the force applied on the roll bar for
rectangular tubes.
45
4.5 The result data of the force applied on the driver’s position and
engine compartment for rectangular tubes.
45
4.6 The ratio of Maximum Yield Stress to Density for Assorted
Metals
47
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 10/24
xiii
LIST OF FIGURES
Figure No. Title Page
1.1 The research methodology in flowchart 7
2.1 The Shell Eco-marathon participant for prototype category and
urban category
12
2.2 An example of chassis of TVR Tuscan 14
2.3 The chassis of the new XK model 16
3.1 The chassis structure of the existing chassis for urban car 21
3.2 The properties of chassis structure from the Solidwork 22
3.3 The analysis of existing chassis applying load on the roll bar 24
3.4 The result of displacement on the roll bar 25
3.5 The deformed shaped of the roll bar after applied load 25
3.6 The result of worst stress on the roll bar 26
3.7 The position of load applied on the driver and engine position 27
3.8 The result of displacement magnitude on driver and engine
position
27
3.9 The vector plots of displacement result in the driver’s position
and engine compartment
28
3.10 The worst stress result in the driver’s position and enginecompartment
28
3.11 The result of Aluminium Pipes T6 6063 displacement analysis 30
3.12 The properties of Aluminium Pipes T6 6063 in Algor 31
4.1 The new chassis design sketching in Solidwork 36
4.2 The forces of 700 N are applied on the roll bar of the chassis 37
4.3 The displacement model of applied forced on the roll bar 38
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 11/24
xiv
4.4 The worst stress of applied forced on the roll bar 38
4.5 The forces apply on the roll bar of the new chassis structure 39
4.6 The worst stress of applied forced on the driver and engineposition
40
4.7 The displacement of applied forced on the driver and engine
position
40
4.8 The worst stress of applied forced on the roll bar 42
4.9 The worst stress of applied forced on the driver and engine
position 43
6.1 The drawing of the existing chassis design 54
6.2 The drawing of the new chassis design 55
6.3 Project planning for FYP 1 66
6.4 Project planning for FYP 2 67
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 12/24
xv
LIST OF SYMBOLS
F Forces
P Pressure
σ True stress, local stress
δ Displacement magnitude
ρ Material density
ν Material volume
A Cross sectional Area D Diameter of the pipes material t Thickness
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 13/24
xvi
LIST OF ABBREVIATIONS
AA Aluminium alloy
FEA Finite Element Analysis
SEM Shell Eco-marathon
FYP Final Year Project
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 14/24
1
CHAPTER 1
INTRODUCTION
1.1 PROJECT BACKGROUND
This chapter basically discuss about the urban car chassis and the best material
used. Currently, urban areas suffer heavily from problems caused by the excessive use
of the private car which also cause the congestion to air and noise pollution. Urban
transport is not only a significant contributor to climate change, but also the main source
of fine particulate matters. The pollutant may cause many cities in the world to exceed
the thresholds given in the world air quality directive.
One of the solutions that can be made is using an urban concept car. The urban
concept car is a car designed to be used in city traffic. It is normally small in size and
not very powerful, but very fuel efficient.
Urban cars are often hailed as the answer to the escalating levels of air
pollution and traffic congestion that result from increases in numbers of larger personal
vehicles. They are intended for use exclusively in or near cities and towns, but they arenot suited to long journeys or fast travel on highways. They are very light, pollute little,
take up a fraction of the space required by most vehicles, cost much less than most cars
and trucks, and can be effectively recycled (Erdmenger and Fuhr, 2005).
As for this studies, the chassis design that been proposed is for one-seated urban
car. Most of the current modern cars use monocoque chassis since it is a single piece of
framework that gives shape to the car. However for this study, tubular space frame
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 15/24
2
chassis is chosen since it is strong enough and have the ability in providing supports for
smaller sports car.
As for material, aluminium is chosen as the best material for the car chassis. It is
because of the material properties itself which can be melted, light in weight, cast,
formed and machined much like these metals and it conducts electric current. According
to the European Aluminium Association (EAA, 2009), aluminium physically,
chemically and mechanically it is a metal like steel, brass, copper, zinc, lead or titanium.
It is in fact often the same equipment and fabrication methods are used as for steel. So,
aluminium will be the best solution in making the chassis framework.
Besides, aluminium is a very light metal with a specific weight of 2.7 g/cm3,
about a third that of steel. For example, the use of aluminium in vehicles reduces dead-
weight and energy consumption while increasing load capacity. Its strength can be
adapted to the application required by modifying the composition of its alloys. This
property is essential in order to make a chassis for a light weight and fuel consumption
urban car (Anonymous, 2009).
Others property for aluminium is it naturally generate a protective oxide coating
and are highly corrosion resistant. Different types of surface treatment such as
anodising, painting or lacquering can further improve this property. It is particularly
useful for applications where protection and conservation are required (Anonymous,
2009).
In terms of Electrical and Thermal Conductivity, aluminium is an excellent heat
and electricity conductor and in relation to its weight is almost twice as good a
conductor as copper. This has made aluminium the most commonly used material in
major power transmission lines (Anonymous, 2009).
Aluminium also a good reflector of visible light as well as heat and together with
its low weight makes it an ideal material for reflectors in for example, light fittings or
rescue blankets. Aluminium is ductile and has a low melting point and density. In a
molten condition it can be processed in a number of ways. Its ductility allows products
of aluminium to be basically formed close to the end of the product’s design
(Anonymous, 2009).
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 16/24
3
Aluminium also is 100 percent recyclable with no downgrading of its qualities.
The re-melting of aluminium requires little energy: only about 5 percent of the energy
required to produce the primary metal initially is needed in the recycling process. The
Table 1.1 below are listed the materials properties of the materials used in this study
(Anonymous, 2009).
Table 1.1: The material properties of aluminium
Materials properties
Density 2600-2800 kg/m3
Melting Point 660 °C
Poisson’s Ratio 0.33
Tensile Strength 230-570 MPa
Yield Strength 215-505 MPa
Percent Elongation 10-25%
Elastic Modulus 70-79 GPa
Source: Anonymous (2010)
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 17/24
4
1.2 PROBLEM STATEMENT
Urban city nowadays suffered from heavy traffic jams by excessive use of
private car. These heavy traffics jams could lead to the air congestion and noise
pollution. The used of an urban car could reduce the traffic problems since it is small in
size. Regarding to the air and noise pollution, using of urban car is recommended since
it is fuel consumption with environmental friendly.
There is a new hydrogen car unveiled in London, UK by Riversimple. This
Riversimple Urban Car (RUC) is powered by fuel cells. These fuels cells combine
hydrogen with oxygen from the air to release energy. What come out from the exhaustpipe are not toxic fumes but water. Even using hydrogen fuel from source to car’s fuel
tank, its carbon emissions for urban driving are only 30 grams/km. The weight of this
hydrogen car is 772 pounds. We can travel 186 miles on just 2.2 pounds of liquid
hydrogen. The Riversimple Urban Car is powered by a cheap, 6-kilowatt fuel. The car’s
top speed is 50 miles per hour (80.4672 kilometres per hour) and it can be accelerated
from 0 to 30 mph (48 km/h) in 5.5 seconds. This hydrogen car should be
commercialized around the world as one of ways in supporting fuel consumption and
environment friendly.
Currently, automobile sector faced problems regarding reducing vehicle weight.
The used of aluminium throughout the chassis could helped to reduce the overall
vehicle weight, hereby reduce the fuel consumption and emission generations. This is
due to the properties of aluminium which light in weight compared to another metals.
Besides, since the demand for more fuel-efficient vehicles increasing and thecost of steel is rising, aluminium will be the best choices to continue play an important
strategic role in reducing vehicle weight. For example, aluminium extrusions offer one
of the lowest investment options for getting aluminium into the vehicle.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 18/24
5
1.3 OBJECTIVE OF THE PROJECT
There are several objectives to be achieved in this study;
1.3.1 To design and develop a chassis for an urban car
1.3.2 To analyze the chassis structure
1.3.3 To propose a new concept of chassis design
1.4 PROJECT SCOPES
This project is focusing on a development of 1-seated urban car chassis using
aluminium and it consists of studying and designing of a 1-seated urban car. This focus
area is done based on the following aspects:
1.4.1 Based on Shell Eco-marathon Asia 2010 rules and regulations
1.4.2 Design a 1-seated urban car chassis using aluminium
1.4.3 Study the used of aluminium as material for the chassis
1.4.4 Analyze the displacement and stress for aluminium as material for the
chassis using ALGOR Fempro
1.4.5 Come out with a general blueprint and specifications of the urban car
1.5 PROJECT METHODOLOGY
The research methodology in the form of flow chart is graphically shown in theFigure 1.1. The research methodology of this project can be classified as follows:
- Analysis of existing chassis design of Shell Eco-marathon (SEM) Asia 2010
- Development of chassis design with different material used.
- Comparison of the analysis result between the current design and the new
design.
Initially, there are various aspect need to be considered to fulfil the design
requirements. The existing chassis was design according to the Shell Eco-marathon
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 19/24
6
rules and regulation which include the size of the chassis, the driver’s position in the
chassis, the material used and spectator safety. The existing chassis of SEM use tubular
stainless steel which assumed to be rigid and heavy.
There are few parameters need to be considered to analyze the chassis structure.
There are stress, displacement magnitude and rotational magnitude. All of these
parameters were applied under same load of 700 N on the roll bar and driver position
as stated in the SEM rules. The stress and strength of the chassis is obtained by analysis
and used to develop the new chassis design.
The new chassis design come out with several enhancement includes the weight
of the chassis, type of element and material used. The new chassis design aims light in
weight with high strength of structure. This is why aluminium rectangular tube been
used replacing the t stainless steel pipes. The aluminium is chosen by the experiment in
Algor to obtain the material properties.
The analyses are also done on the different type of element which is tubular
space frame and hollow rectangular space frame. Each of these two elements has
different displacement magnitude and stress under certain load applied. The result of
the analysis will be used to obtain the most high strength structure of the chassis. The
analysis is done on different size of tubes.
After done analyzing both existing and new design of the chassis, there are
several comparisons to be made to ensure that the development of new chassis has
fulfilled the design requirement such as light in weight. Finally, the discussion upon all
analyses results is made and some recommendations are proposed.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 20/24
7
Figure 1.1: The research methodology in flowchart
Literature
Review
Start
Design the new
chassis model
Editing the
existing chassis
design of SEM
Experimental setup
for aluminium
Analyze the
chassis
Analyze the
chassis
Comparison of the analysis result
Discussion
End
AcceptableAcceptable Acceptable
Collecting data
(The properties of
aluminium)
No NoNo
Yes
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 21/24
8
1.6 STRUCTURE OF THESIS
Chapter 1 introduced the overall view of this study upon chassis development.
The overviews begin with the project’s background which clarifies the concept and
main concern of this study. For the problem statement section, there are sort of
discussion about current industrial problems upon the design of chassis and material
used for chassis. Besides, the objectives and scopes are also being clarified in this
chapter and it is important to construct the flow of the process done in this study. The
project’s methodology proposed the flow chart and discussing the method used for
analyzing the chassis.
The main concern in chapter 2 is the literature review. Basically, literature
review give readers the detailed explanation involving scopes of this project. Since the
design is based on the rules and regulation of SEM, there are several overviews upon
what it is all about and the main concern in designing the vehicle during competition.
Other than that, the advantages and disadvantages of using aluminium for a chassis
also have been discussed in this chapter. Both advantages and disadvantages are based
on the current technologies use in industries.
As for the chapter 3, there will some explanations about Finite Element
Analysis and parameters involved in this study. The result of analyses on the existing
chassis design also is shown in this chapter. Considering aluminium as the material for
new chassis, there will be a material experiment using Algor to determine the
properties of aluminium. Besides, the type of aluminium used which is Aluminium
Alloy T6 also clarified in this chapter.
The new chassis design proposed in this study will be shown in chapter 4. The
full analyses of the chassis are made same as the existing chassis in chapter 3.
However, there will be three readings for the result data according to different sizes of
the pipes. The displacement magnitude and worst stress of the chassis is observed after
load is applied. Besides that, the weight of the chassis also consider in the analysis
result.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 22/24
9
The chapter 5 will be the final chapter in this thesis. Overall conclusion upon
this study will be clarified here. The assumption made before also to be discussed in
this chapter. Besides, there is also the project recommendation which is proposed few
recommendations and ideas improving this study.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 23/24
10
CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
Chapter 2 consists of few sections which are the section (2.2), Introduction of
Shell Eco-marathon Asia 2010 and the type of Chassis of an Urban Car and Current
Design (2.3). For section (2.4), there are advantages and disadvantages of using
aluminium for a chassis including (2.4.1), the advantages and section (2.4.2) the
disadvantages. The final section will be the summary of the chapter 2 (2.5).
The chronology of this chapter has been properly organized according to the
sequence of this study. In this chapter, the readers will get chances to understand the
idea on how aluminium would be the best aluminium for chassis and also the concept of
the chassis design. The introduction of Shell Eco-marathon Asia 2010 in the section
(2.2) clarifies the concept of the competition, rules and regulations need to be follow by
the participant in designing the vehicle. Section (2.3) gives explanation upon chassis
types and current chassis used in industry. This section also clarified the type of chassis
used in this study. The section (2.4) will elaborate the advantages and disadvantages of using aluminium as chassis based on the research from current automotive industry.
This section also indicates the reasons of choosing aluminium as chassis. As for
summary section, there will be an overall overview of what have been discussed in this
chapter.
8/3/2019 Fazliana Fauzan ( CD 4982 )
http://slidepdf.com/reader/full/fazliana-fauzan-cd-4982- 24/24
11
2.2 INTRODUCTION OF SHELL ECO-MARATHON ASIA 2010
Shell Eco-marathon challenges high school and college student teams from
around the world to design, build and test energy efficient vehicles. With annual events
in the Americas, Europe and Asia, the winner is the team that goes furthers distance
using the least amount of energy. This event also affords an outstanding engagement
opportunity for current and future leaders who are passionate about finding sustainable
solutions to the world’s energy challenge.
There are two categories contested; urban category and prototype category. For
this year, Malaysia is the host for this challenge for Asia stages. In order to support this
event, Universiti Malaysia Pahang has sent two teams to participate which include both
categories. For this project, the chassis design is based on the design of SAE-UMP
Chapter Team Urban Concept. Since we participating this event, the design of the
chassis is based on the rules and regulation state by Shell Asia which include design and
safety part.
Basically, this challenge is about fuel consumption which needs further distance
with less fuel. So, we need to do a lot of weight reduction to the vehicle which for this
project; urban car. Due to this problem, choosing material and design become important
for this project. According to the Shell Eco-marathon Official Website (2010), here is
the latest record in Shell Eco-marathon. The NTNU Team, Norges Tekiske og
Naturvitenskapelige Universitet, Norway is 1,246km/l (2,930.77 mpg) and the best
overall Urban Concept fuel consumption is 848km/l (1, 994.62 mpg) in 2008.
Designing the chassis of urban category, the entire car should fulfill the rules
and regulation needs. One of the rules is that the vehicle must be equipped with an
effective roll bar that extends 5cm around driver’s helmet when seated in normal
driving position with safety belts fastened. Any roll bar must be capable of withstanding
a static vertical and horizontal load of 700N (~70 kg) without deforming as stated in the
Shell Eco Marathon Asia Official Rules 2010-Chapter 1). The Figure 2.1 shows the
picture during the event of Shell Eco-marathon Asia 2010 which held in Sepang
International Circuit on 9th
July until 11th
July 2010.
top related